Chemically bonded refractory



106. COMPQSITIONS, Q COATlNG 0R PLASTIC. Vg Patented Oct 15, 1940 UNITED STATES Cross Reference Examiner 2,218,243

PATENT OFFICE v 2,218,243 CHEMICALLY BONDED REFRACTORY tion of Canada No Drawing. Origin Serial No. 138,742.

11.: l e application April 24, 1937,

Divided and this application April 17, 1939, Serial No. 268,336

4 Claims.

This invention relates to chemically bonded plastic and granular materials, including refractories, and is particularly directed to providing a bonded material of uniformly high strength 6 throughout when a soluble silicate is used in binding together finely divided or granular particles, as in the production of cements, mortars and molded masses of refractory materials.

In the use of a silicate binder it has been observed that there is an actual travel or migration of the soluble silicate to the surface of the bonded material during the process of "drying, resulting in an increased concentration of the binder at v the very surface and a correspondingly weakened 1 internal portions. Not infrequently this phenomenon takes place to such an extent that the surface can hardly be indented with a knife, while the internal portion can be readily crumbled in the fingers. Analysis of the exterior and interior portions of a refractory or other material bonded with sodium silicate shows the extent to which such migration takes place.

It is known that silicate solutions are readily decomposed by acids or other electrolytes, setting to form gels of silicic acid, whereby the solutions lose their valuable adhesive properties. In United States Patent 631,719, August 22, 1899, Imschenetzky discloses a method in which asbestos is treated with a solution of sodium silicate containing sodium bicarbonate. He stated that colloidal silica is precipitated, permitting the mass to be handled and immersed in a bath of sodium bicarbonate, as a result of which all of the remaining sodium silicate is decomposed, with the precipitation of silica. The sodium carbonate formed in the reaction is recovered.

Applicants have found that, in plastic and granular materials bonded with soluble silicate, the decomposition of the silicate with precipita- 40 tion of all contained silica results in almost complete lack of strength. It has been discovered, however, that the normal strength of the bond produced by a soluble silicate can be greatly increased and uniformly distributed throughout the mass of molded granular and plastic material. It is the object of the present invention to provide such a product and a method of producing it. The invention thus contemplates forming in situ in the molded or shaped mass a continuous, gelatinous and siliceous structure, containing a substantial portion of the silicate bond in the undecomposed condition, which prevents migration and insures strength. This may involve actual but incomplete precipitation in situ of a 55 silicic gel containing soluble silicate, or only the forma ion of a gel without decomposition of the silicate. The mechanism of the formation of the structure is not fully understood but the coagulation of the silicate or other reaction between the silicate and the anti-migration agent within 5 the shaped mass is important to avoid migration and to insure the desired strength of the bond.

In carrying out the invention, there is mixed with sodium silicate a suitable proportion of an antm and this mixture is unio formly incorporated in the mass of crushed or granular material to be bonded, in such a manner that the anti-migration agent causes the formation, in situ of the continuous, gelatinous, and siliceous structure described. 1 Ks anti-migritiErTaTgiit", there may be used the car ona e aicarBonate chlorate nitrite and nitraE salts of sodium and tassium. UnliEe s rong acids mama salts, these agents when used in suitable proportion do 20 not cause immediate precipitation of gelatinous silica, but permit the gel formation of the character described to take place in situ and thus effectively prevent migration.

Of these reagents only the normal carbonate is efiectiye when mixed with silicate in solution.

It is less effective when mixed with ,dry, ili;cat For the latter, other anti-migration agents are normally employed.

Thus the normal carbonate is mixed with wet sodium silica g and the we mixture is uniformly incorporated in the material to be bonded. When molded or shaped in position the anti-migration agent causes the formation of the continuous gel bility in position of the. binder with the resultant increased strength of the product.

El e other reagents are mixed with dry silicate,

flwyi l slslmifmmlyinmrmmkggg s of crushed or granular material to be bonded and g wmmw promp y ormed into shape or placed in i s al a'fiHTil'Oduces the desired results.

' en or ormed mass has hardened it has a strength as much as several hundred per cent higher than that obtained with a similar binder without the anti-migration agent. Morethrough the mass is of great importance. If greatest strength is not required, the amount of the soluble silicate binder used may be reduced, with the consequent saving in cost as well as increased refractoriness in the product.

structure as the material dries and insures sta- 35 position. The continuous gel structure fiEIlS over the uniform distribution of the strength It is not practicable to specify a definite per- 5" centage of each agent to be used under all circumstances, owing to the wide range in the proportion of soluble silicate incorporated in different mixtures, the variation in the silica-alkali ra- This application is a division of application Serial No. 138,742 filed April 24, 1937.

We claim:

1. In the preparation of chemically bonded 5 tie of different soluble silicates, and the variaplastic and granular materials, the method which tions in the character of the materials to be comprises uniformly mixing with the material to bonded. This factors must be considered in debe bonded a soluble silicate and not less than termining the choice and optimum amount of an- 's'ubstaii .4% nor e an su s an 1a y ti-migration agent to be used. Furthermore, the 2% of said material rite 10 time required to mold the refractory or put it in and'nitrate salts of sodium and po m, @0111; place indicates the delay required in the formahibitmlgrattcrrot-saidmcatewimmiss tion of the gel structure. and insure uniform bonding of the latter.

The selection of an anti-migration agent and A method of inhibiting migration Within a the determination of the quantity to be used i mass of granular materials containing soluble sili- 15 each particular combination should be made ex- Cate as a bonding a Which comprises perimentally. The following table illustrates the ly c p atin within the mass not e s affect of various percentages of sodium bicarthan substantially 0.4% nor substantially more bonate as an anti-migration agent in a, refraethan 2% of at least one or the nitrite and nitrate tory bonded with sodium silicate. salts of sodium and potassium.

3. In the preparation of plastic and granular AL, Tensile refractory materials bonded with a soluble silipemnt bicarbonate strfiangthin cate, the method of preventing the migration of & -83f said silicate within the mass of material which consists in incorporating in the mixture of ag- 25 on 165 gregate and soluble silicate at least one of the 2;, g8 nitrite and nitrate salts of sodium and potassium niz- 385 in the proportion of not less than substantially 12 233 0.4% nor more than substantially 2% of the ma- 1 e 290 terial to be bonded to cause the formation in situ 20 225 of a continuous, gelatinous and siliceous structure containing a substantial proportion of un- It is evident that in th s case 1.3% is approxdecomposed Si11cate unately Percentage Sodlum 4. A composition of matter to be incorporated 35 i gz' g g figg z 3 i g ggg s with plastic and granular materials to bond the Sodium bicarbonate revials the ef'fect of latter comprising sodium silicate and as an anticomposition of too much of the sodium silicate, 3 at.1east one of nitrite and leaving an unsatisfactory gel structure to form mtrajte sdlum and potasslum the the bond portion of said agent being not less than substan- 0 The following examples illustrate the effect of 04% more than substantlauy 2% of various anti-migration agents and W111, t some the material to be bonded to cause the formation extent, serve as a guide in the choi e of th o t in said materials when wet of a continuous gelatsuitable agent and the determination of the inous structure, containing a substantial proporamount to be used. tion of undecomposed silicate.

anti-migration agent No anti Refractory material Q H T z iga r i t uan l y ensi e tensn use era.

Sodium chlorate 2. 0 375 105 Sodium nitrate 2.0 330 185 Various mixtures of basic and neutral refractories %%;g g$ Potassium chlorate 2.0 555 320 Potassium nitrite l. 5 480 320 Clay Sodium carbonate 2.0 475 300 Neutral refractory Sodium biearbonate 0.7 670 290 D Sodium nitrite l. 5 730 240 FRANK EUGENE LATHE. o NORMAN PERCY PITT.

LISLE HODNE'IT. 

